Article for prepping/flattening a floor

ABSTRACT

An article, system and method for flattening a three dimensional depression within a substrate floor. A straight edge is applied in a progressive X and Y grid fashion across the depression, with varying levels of shims defining contact locations, thereby establishing a floor template identifying common depths of depression at overlapping perimeter defined boundaries. One or more thermo-polymer sheets is resized to define an outer perimeter matching that of a perimeter boundary. A subset thickness of the sheet is incised around its outer perimeter to establish a feathering effect upon the sheet prior to it overlaying the boundary perimeter and prior to sizing and application of additional overlapping sheets up to an outermost boundary corresponding to a shallowest depression.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 12/250,232, filed Oct. 13, 2008.

FIELD OF THE INVENTION

The present invention discloses a system, article and method forflattening depressions in a base surface, including wood and concrete,and prior to the application of a floor overlay.

BACKGROUND OF THE INVENTION

The prior art is documented with techniques for flattening or leveling abase surface, such as a wooden subflooring or poured concretefoundation, and prior to the installation of a floor covering, such as awood, carpet or laminate style material including but not limited tovinyl. In one known prior art application, asphalt roofing shingles hasbeen used for “filling” in such depressions. Other “fill-in”compositions are known for use in filling a depression in a floorconstruction, one example of which being disclosed in U.S. Pat. No.7,241,819 to Bowe.

SUMMARY OF THE INVENTION

The present invention discloses an article, system and method ofapplication for flattening a regional floor depression within concreteor other material substrate flooring. A plurality of planar sheets andassociated shims are provided, with a selected uncut sheet (or otherelongated straight edge) being employed in a progressive X and Y gridapplied fashion with varying levels of shims defining contact locationsand for quickly establishing a floor template identifying common depthsof depression existing within regional floor depression.

Each plurality of commonly marked depths establishes a perimeter definedboundary, with the deepest boundary typically being central mostlocated. Progressively shallower depths define additional encirclingboundaries, so that the shallow-most depth defines the outer perimeterof the floor depression.

At this point, each of the sheets is trimmed to define an outerperimeter roughly matching that of a selected perimeter extendingboundary. A subset thickness ranging from such as 0.25 to 0.50 of thethickness of the sheet (for example 1/16″ of a ⅛″ thick sheet) is thenremoved around its outer perimeter, such as to a band width from between2½-4 inches, by a box cutter or other suitable knife edge, and in orderto establish a feathering effect upon the sheet overlaying itsassociated boundary perimeter.

To assist in the sectioning/feathering of the individual sheets ofmaterial to arrive at their subset defined thicknesses can includemanufacturing the sheet from multiple ply materials, such as which areheld together by an adhesive or other suitable agent. Upon beingincised, removal of the desired outer band of material can be assistedby the application of a wax release agent, or the like, between thesubstrate layers.

An adhesive tacky layer can also be applied to an exposed surface of thesheet (this facing downwardly when applied over its correspondingrecessed boundary), and with a peel away release layer exposing thetacky adhesive. Either or both of a mold inhibitor or a moistureimpervious layer can also be entrained within the thermo-polymerconstruction of the sheets (this particularly useful in below gradebasement applications).

Specified applications of the sheets (again typically below grade) canfurther require that they exhibit substantially waterproof performance,this particularly desirous when providing a substrate application towood flooring. The sheets can also be constructed from other materials,such as a vinyl, when in use with concrete floors.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the attached drawings, when read incombination with the following detailed description, wherein likereference numerals refer to like parts throughout the several views, andin which:

FIG. 1 is an environmental illustration of a selected level edge beingapplied in a progressive and iterative xy grid fashion over a recessedarea and, in combination with varying pluralities of shims slidablydisplaced along a bottom edge of the straight edge to contactinglocations with the recessed area, establishing boundary patternscorresponding to varying depth levels existing within the recessed area;

FIG. 2 is an exemplary illustration of a boundary template constructedaccording to the description of FIG. 1;

FIG. 3 is an enlarged partial edge perspective of a thermo-polymer sheetaccording to one embodiment of the inventions and exhibiting suchfeatures as a subset thickness defined plies and a tacky adhesive layerrevealed by a release wax layer;

FIGS. 4A-4C illustrate additional examples of boundary defined patterns,similar to that shown in FIG. 2, and which can each exhibit a differingnumber of individual boundary defined depths;

FIG. 5 is an illustration of the succeeding steps of a given sheet beingtrimmed to define an outer perimeter roughly matching that of a selectedperimeter extending boundary, following which a subset thickness of thesheet is removed around its outer perimeter in order to establish afeathering effect (i.e. a transitional boundary) and upon the sheetoverlaying its associated boundary perimeter;

FIG. 5A is an enlarged partial illustration of the area designated at 5Ain FIG. 5 and further showing the stepped configuration defined by thefeathered (transitional) perimeter edge;

FIG. 6 is an exemplary illustration of a double boundary application(such as also designated by the template design of FIG. 4B) and by whicha pair of perimeter boundary resized and edge feathered sheets areapplied to roughly fill in the area defined depression;

FIG. 7 is a level edge environmental view of a dual layer applicationsuch as shown in FIG. 6, and over which a finishing flooring is applied;

FIG. 8 is a level edge environmental view of a four layer application ofa template and sheet overlay design according to a further possiblevariant of the present inventions; and

FIG. 9 is an enlarged partial perspective of a knife edge being employedto remove a boundary extending and subset thickness portion of apreviously reduced (resized) sheet, and in order to create the desiredfeathering (transitional layering) effect.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIG. 1 is an environmental illustration is shown at 10of a system, method of application and sheet article for flattening athree dimensional depression existing within a floor surface. Aspreviously described, the present invention discloses a novel system,method and article for quickly establishing individual pluralities ofdepth markings, these being interconnected to defining overlappingperimeter boundaries corresponding to various depth levels within theregionalized depression.

Additional features include the provision of a straight edge guidewhich, in combination with a plurality of shims, are manipulated in asucceeding xy grid applied fashion, and in order to establish thevarying depth levels of the perimeter boundaries. A plurality ofindividual sheets, each exhibiting a multi-ply construction, areindividually resized to correspond to each of the overlapping andindicia marked perimeter boundaries.

A perimeter extending band of material is further incised from one ormore of the ply layers, this in order to provide a stepped/featheringeffect when placed within the depression. The floor flatteningsystem/method/article provides an improvement over prior techniques, andin order to establish a flattened substrate over which is applied afinish flooring, such as a wood, vinyl or ceramic/stone/marble material.

Referring again to FIG. 1, an elongated article exhibits a straight edgeand which is adapted to overlay a floor depression, see asrepresentatively shown at 12, in each of a plurality of incrementallyspaced (xy grid) locations. The elongated article is, in one variant, isa ruler-type device (see as shown at 14 in FIG. 1), such as a level ofup to 8′ in running length, and exhibiting a downwardly facing straightedge (see as further shown at 16). The straight edge can also beestablished by an underside edge 18 of a sheet 20 of material, and suchas which is incorporated as an overlay article as subsequentlydescribed.

The straight edge guide 14 (or selected planar sheet 18) is employed ina progressive X and Y grid applied fashion (see additional parallelspaced locations 18′ and 18″ as well as crosswise spaced apart locations22, 22′ and 22″). The straight edge guide is typically advanced inincrementing fashion a foot (1′) for each xy spaced interval (see asbest shown in the boundary template construction of FIG. 2).

Varying plurality of shims are provided, see at 24, 26, 28, et seq.,each further having a length, width and thickness. The present inventionincludes any number of shims (such as a single shim or two, three ormore stacked shims) placed between the straight edge and a locationalong the floor depression (see as shown in FIG. 1). The shims areslided to locations in which its/their uppermost location contacts thedownwardly facing surface of the straight, edge, with its/theirlowermost location contacting the floor surface. In this fashion, theindividual plurality of shims each define contact locations for quicklyestablishing a floor template identifying common depths of depressionexisting within regional floor depression.

A marking indicia, such as a pencil 30 as shown in FIG. 1, is providedand is employed to mark each contact location established asingle/pair/multi-stacked arrangement of shims. As again shown in FIG.2, each plurality of commonly marked depths establishes a perimeterdefined boundary, with a deepest boundary 32 typically being centralmost located. Progressively shallower depths define additionalencircling boundaries, see at 34 and 36, so that the shallow-most depthdefines the outer perimeter of the floor depression.

As further shown in FIG. 2, the marking indicia 30 (FIG. 1) is employedfor identifying locations upon the floor surface in which equal numbersof shims (A=1, B=2 or C=3) is/are in contact with both an underside ofsaid straight edge and the floor surface. The marking indiciainterconnects the individual pluralities of marked locations, each ofwhich corresponds to an equal number of shims, and in order to establisheach of the perimeter defined boundaries 32, 34 and 36. Referring toFIGS. 4A-4C, illustrated at 38, 40 and 42, respectively, are additionalexamples of boundary defined patterns, similar to that shown in FIG. 2,and which can each exhibit a differing number of individual boundarydefined depths.

Referring now to FIG. 3, an enlarged partial edge perspective isgenerally referenced at 44 of a thermo-polymer sheet according to oneembodiment of the present invention, (it being understood that asuitable sheet exhibiting any possible material content can also beemployed) and exhibiting such features as subset thickness defined asindividual plies of material 46, 48 and 50, as well as an exposed facedefined tacky adhesive layer 52, this revealed by an optional releaseplastic or wax-like layer 54. As will be further described, the tackylayer 52 provides an adhering surface for securing the sheet upon anestablished perimeter boundary. It is also envisioned and understoodthat the shims can each likewise exhibit a tacky surface layer, such aswhich will facilitate multiple stacking of shims when applying in thefashion shown at 26 and 28 in FIG. 1. The multi-ply sheet 44 of FIG. 3is also understood as being the same as shown at 20 in FIG. 1 and, inone preferred variant, is provided as 42″×42″ (or greater such as up 8′)in dimension, with an overall thickness of ⅛″.

The sheet can include either a pair of plies (or three as shown in FIG.3), such as each exhibiting a subset thickness of 1/16″ (as in theinstance of a two ply sheet) or as little as ¼ to ½ of a ¼″ thick sheet.One or more intermediate boundary layers, see as shown at 56 and 58, canfurther includes a wax release layer to facilitate subsequent incisingand removal of a selected subset ply (as will be discussed). The sheetsof material (including their respective plies) can further be treatedwith such as moisture impervious and/or mold inhibiting material,depending upon the eventual application of the sheeting in theflattening application. It is further understood that the thermo-polymersheet construction (such as which is employed in an elevated or abovegrade wood or ceramic flooring application) can be substituted in onepotential application by a vinyl material and multi-ply sheeting whichis utilized in a below grade application, such as upon a basementconcrete surface.

Referring now to FIG. 5, an illustration is shown at 60 of thesucceeding steps of a given sheet being trimmed to define an outerperimeter roughly matching that of a selected perimeter extendingboundary, such as shown by any of interconnected boundaries 32, 34 and36 in FIG. 2 or any of the individual single, double overlapping, ortriple overlapping shim patterns successively illustrated in FIGS.4A-4C. In a first resizing step, an incising tool, see knife 62, isemployed to cut/resize the outer perimeter of the sheet to generallymatch the boundary defined perimeter over which the sheet will besubsequently applied in a flattening operation. In this first incisingoperation, all plies of sheet material are removed about its outerperiphery, and in order that the sheets two dimensional imprint matchesthe boundary pattern. One technique for achieving a correct dimensioningis in applying an inking or chalk indicia upon the boundary layer, overwhich the as yet un-sectioned sheet is placed, and in order to define amarking template on an adhering surface of the sheet to assist insubsequent knife edge (e.g. box cutter or the like) resizing.

Following the first incising operation, the knife edge is employed in asecond, subsequent operation (see at 62′) and by which a subsetthickness of the sheet (such as one or more of its subset thicknessdefined plies) is removed, such as a band of material around its outerperimeter, in order to establish a feathering effect (i.e. atransitional boundary) upon the sheet overlaying its associated boundaryperimeter. A preferred width of the removed bond of material may measurein a range of 1″-6″ depending upon whether employed in a corner, wall,or mid-floor application. Shown in FIG. 5A is an enlarged partialillustration of the area designated at 5A in FIG. 5, and further showingthe stepped configuration defined by the feathered (transitional)perimeter edge created by sectioning an outer edge band portion, see at64, from the outer perimeter of the sheet material, and so that astepped pattern is established by a perimeter most extending substratelayer 66 and a previously conjoined portion 68 of an upper layer fromwhich the outer edge band portion 64 is removed.

Referring to FIG. 6, an exemplary illustration is provided at 70 of adouble boundary application (such as also designated by the templatedesign of FIG. 4B) and by which a pair of perimeter boundary resized andedge feathered sheets, see at 72 and 74, are applied to roughly fill inthe area defined depression. FIG. 7 illustrates at 76 a level edgeenvironmental view of a dual layer application, such as shown at 72 and74 in FIG. 6, and over which a finishing flooring 78 (again includingany of a wood, vinyl, ceramic or other type material) is applied. FIG. 8is a succeeding level edge environmental view, see at 80 of a four layer(see at 82, 84, and 86) overlay sheet construction according to a yetfurther potential application and for preparing/flattening a substratefor eventual application of a finish flooring 90. The illustrations ofFIGS. 7 and 8 further indicate that the outwardly stepped/feathering ofthe perimeter defined edges can be exhibited so as to face downwardly(FIG. 7) or upwardly (FIG. 8) in either of a consistently appliedfashion.

Referring finally to FIG. 9, an enlarged partial perspective is shown at92 of a knife edge (at 94) being employed to remove a boundary extendingand subset thickness portion 96 of a previously reduced (resized) sheet,again in order to create the desired feathering (transitional layering)effect. FIG. 9 is generally similar to the configuration illustrated inFIG. 5, and which better illustrates the feature of the wax releaselayer 98 revealed by the removal of the outer/upper band of material 96corresponding to an upper ply of material. It is again understood that atwo ply sheet material (as further referenced by plies 100 and 102 inFIG. 9) or a three or more ply sheet material can be provided accordingto the desires of the user.

FIG. 9 also illustrates the ability to section equal dimensioned(length, width and thickness) shims 104, 106 and 108, such as from thepreviously excised band 96 of ply material. While this provides onepossible application for producing desired shim material, it is alsoenvisioned that the desired shims are separately provided separately(such as each having a desired but non-limiting thickness of 1/16″-⅛″)or which are sectioned from an uncut sheet of material, or from aninitially excised and outermost full depth portion of a sheet (see againoperation 62 in FIG. 5).

A related method is also disclosed for flattening a depression in afloor surface, and which includes the steps of overlaying a straightedge having an underside across the floor depression, inserting at leastone shim between said straight edge and a location along the floordepression, and displacing the individual numbers of shims along thestraight edge until coming into contact with both its underside and thefloor surface. Additional steps include marking individual contactlocations established by one or more shims along the straight edge,successively advancing the straight edge in spaced and incrementalfashion along the depression between marking successive pluralities ofcontact locations, and interconnecting at least one individual pluralityof marked locations corresponding to an equal number of shims toestablish a perimeter defined boundary. Further steps include providinga sheet exhibiting a specified length, width and thickness andexhibiting at least first and second plies defining subset thicknesses,sectioning an outer perimeter of the sheet to match the perimeterdefined boundary, subsequently removing an outermost band of at leastone of the plies of material, to define a stepped pattern and applyingthe resized and feathered edged sheet over the perimeter definedboundary.

Additional method steps include establishing a deepest perimeter definedboundary at a central most located within the depression, withprogressively shallower depths defining additional and encirclingperimeter boundaries so that a shallow-most depth defines an outermostperimeter boundary of the floor depression, as well as coating the sheetwith at least one of a moisture impervious membrane and a moldinhibitor. Other method steps include constructing said sheet from atleast one of a thermo-polymer and a vinyl material, applying a wax layerbetween the plies of sheet material, and applying a tacky layer appliedto an exposed surface of at least one of the sheet and shims.

The present inventions also disclose a sheet for flattening a depressionin a floor surface, and which includes a body exhibiting a specifiedlength, width and thickness and further having at least first and secondplies defining subset thicknesses. A wax, or other suitable multi-plyrelease layer is interposed between the plies of sheet material. Thesheet is secured by either of a plurality of underlayment ring shanknails (not shown) or through the provision of a tacky layer applied toan exposed surface of the sheet and which is covered by a peel awaylayer. The use of a tacky layer is particularly applicable to a vinylsheet exhibiting a clean adhering surface to which the tacky layer ispre-applied.

Other sheet article features again include the body exhibiting aspecified shape and size and further having a total thickness no greaterthan ¼″, with a selected ply thickness of between ¼ and ½ of the totalthickness. The sheet may also be coated with at least one of a moistureimpervious membrane and a mold inhibitor and can also be constructed (ina few of numerous non-limiting applications) of a thermo-polymer or avinyl material.

Having described my invention, other and additional preferredembodiments will become apparent to those skilled in the art to which itpertains and without deviating from the scope of the appended claims.

1. A sheet for flattening a depression in a floor surface, comprising: abody exhibiting a specified length, width and thickness and furthercomprising at least first and second plies defining subset thicknesses;and a separating layer interposed between said plies of sheet material;at least one of an outer perimeter of said body and an outermost band ofmaterial of a selected ply being removed prior to said body beingsecured to a surface of the depression.
 2. The sheet as described inclaim 1, said body exhibiting a specified shape and size and furthercomprising a total thickness no greater than ¼″, with a selected plythickness of between ¼ and ½ said total thickness.
 3. The sheet asdescribed in claim 1, said sheet having a specified shape and size andbeing coated with at least one of a moisture impervious membrane and amold inhibitor.
 4. The sheet as described in claim 1, said sheet havinga specified shape and size and being constructed of at least one of athermo-polymer and a vinyl material.
 5. The sheet as described in claim1, further comprising a plurality of underlayment ring shank nails forsecuring said body within said depression.
 6. The sheet as described inclaim 1, further comprising a tacky layer applied to an exposed surfaceof said sheet and which is covered by a peel-away layer.